EP1476931B1

EP1476931B1 - Dual transformer high frequency battery charger

Info

Publication number: EP1476931B1
Application number: EP03707515.7A
Authority: EP
Inventors: Michael Krieger; Bruce Randolph
Original assignee: Vector Products Inc
Current assignee: Vector Products Inc
Priority date: 2002-01-25
Filing date: 2003-01-24
Publication date: 2017-11-01
Anticipated expiration: 2023-01-24
Also published as: ES2648976T3; US7564223B2; EP1476931A2; WO2003065541A1; US20030141845A1; EP1476931A4; CN1669200A; AU2003209360A1; US6822425B2; WO2003065537A2; CA2485040A1; CA2474632C; CN1643762A; CA2474632A1; EP1476930A1; WO2003065537B1; US20080185996A1; CN100511917C; MXPA04007211A; WO2003065537A3

Description

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to a battery charger or booster and in particular to a high frequency charger.

Technical Background

Dual-mode battery chargers currently exist. When operated in a first mode, the battery charger delivers a high current output for a short duration of time. This short duration, high current can be used to jump-start a vehicle with a dead battery. In a second mode, the battery charger provides a low current output that is used to charge the battery back to its full charge. Known dual-mode battery chargers typically use a single large transformer to achieve the dual-mode capability. The single transformer is usually a linear type transformer. A tap of a primary winding of the transformer is changed in order to achieve the dual capability with the linear-type transformer. As the tap of the transformer is changed, the output voltage, and hence, according to Ohm's Law, the output current of the transformer is changed, resulting in the dual-mode capability. Use of a single transformer for both modes of operation has the advantage of being very cost-efficient and very effective.
However, this approach also has several disadvantages. One of the disadvantages is that single transformer battery chargers are very large and cumbersome. Standard linear transformers require iron for their cores, adding to the weight of the battery charger. They also require orders of magnitude more wire to form their windings than do high frequency chargers, again adding to the weight of the battery charger. Additionally, although the linear transformer can provide a high current output, the high current output can only be provided for a very short period of time. As the transformer operates in high current mode, it generates an excessive amount of heat. In fact, so much heat may be generated that the transformer actually melts down. If a meltdown occurs, the transformer will not operate in either the high current mode or the low current mode. Linear transformers are also very lossy in terms of magnetic losses and eddy current losses, resulting in inefficiency. Additionally, a characteristic of liquid electrolyte type batteries, particularly lead acid batteries used in vehicles, is that chemical compound deposits slowly build up on the plates to partially or entirely cover and displace the normal plate surfaces. Low current recharging is inadequate in that it can not, as such, sufficiently remove such deposits that with the passage of time crystallize and choke the battery plates by interfering with electrolyte movement. When this occurs a battery may still appear to have taken a charge and even the electrolyte may check as being correct, but the battery does not hold the charge because the plates are effectively shorted. Batteries using other electrolytes also face reclaiming, maintenance and charging problems that need to be successfully addressed.
Thus, there is a need for a method to release the deposits that are built up on the plate surfaces, where the deposits may either go back into the solution or be broken up. There is also a need for a simple and lightweight dual-mode battery charger. The battery charger should be able to provide a high current output that is sufficient to start an automobile or other vehicle with a dead battery, yet be easy to construct and safe to operate.
US-A1-5,166,595 described a switch mode batter charging system including a switch mode power supply, which can switch between an equalize and a float mode of operation.

SUMMARY OF THE INVENTION

Aspects of the invention are set out in the independent claim and preferred features are set out in the dependent claims. There is described herein a high frequency charger that includes a charge circuit and a boost circuit. In a preferred embodiment, the charge circuit includes a first high frequency transformer. A switch switches this first high frequency transformer at a predetermined frequency. The boost circuit includes a second high frequency transformer that is separate from the first high frequency transformer in the charge circuit. The first and second high frequency transformers are operated in a similar manner. However, the boost circuit is adapted provide a high current that can be used to jump-start a vehicle with a depleted battery.
In a preferred embodiment, a PWM controller provides a driving signal to the switch such that the transformer of the charge circuit is switched to output a pulse. The pulse output of the charge circuit can be used to condition the battery.
As noted, the transformer in the charge circuit and the transformer in the boost circuit are preferably separate from each other, that is, there are two transformers and associated circuits. Thus, the battery charger is not dependent on the same transformer for both standard charging and boosting.
For example, if the transformer in a conventional charger burns out while performing a boost function, all the functionality of the charger may be lost, as one transformer is used for both functions. However, in the present embodiment, either of the transformers still operates even if the other transformer is disabled for some reason.
A control circuit for a high frequency charger is also provided. In an exemplary embodiment, the control circuit includes a pulse width modulation (PWM) controller having a reference voltage input, a control input, and an output for a control signal. A switch receives the control signal and is switched on and off in response to the control signal. A voltage divider network divides the voltage applied to the reference voltage input and the control input. A duty cycle of the control signal output from the PWM controller varies based on the percentage of the reference voltage that is applied to the control.
In a further embodiment, the voltage divider network comprises a first resistor having a first terminal connected to the reference voltage input and a second terminal connected to the control input. A plurality of second resistors each has a first terminal connected to the second terminal of the first resistor and a second terminal. A plurality of transistors are also provided, each having a first electrode connected to the second terminal of one of the second resistors, a second electrode that is grounded, and a third electrode receiving an enable signal. The enable signal turns the transistors on and off, selectively connecting one of the second resistors to ground.
There is described herein a computer-readable storage medium for use with a computer for controlling a high frequency charger including a charge circuit having a first high frequency transformer; a first switch switching the first high frequency transformer at a predetermined frequency for producing a charge signal in a first mode of operation; the charge circuit operating in at least one of a pulse mode and a charge mode; and a selector for selecting one of the charge mode and the pulse mode, the computer-readable information storage medium storing computer-readable program code for causing the computer to perform the steps of: detecting a selected mode of operation for the charger; and when a pulse mode is selected, a) generating a driving signal for the first switch for a first period of time; b) disabling the first switch for a second period of time; and c) returning to step a).
The above and other features of the invention, along with attendant benefits and advantages will become apparent from the following detailed description when considered with the accompanying drawings.

BRIEF DESCRIPTION OF THE FIGURES

Figure 1 is a block diagram showing a dual high frequency charger according to an embodiment of the present invention.
Figure 2 is a diagram of waveforms generated by control circuits according to an embodiment of the present invention.
Figure 3 is a circuit schematic in partial block diagram form showing an embodiment of the pulse enable circuit and the pulse width modulation controller shown in Figure 1.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to Figure 1, there is shown a high frequency charger, according one embodiment of the invention, which includes a high frequency transformer portion 8. The high frequency transformer portion 8 typically receives a DC signal as its input. The DC signal can be provided from a battery or from an AC input. In the embodiment illustrated, an AC input 2, which may be provided by a typical wall-socket, is coupled to a filter 4, for example, a pi filter or an LC filter. The filter 4 is used to smooth and clean the AC input. An AC signal output from the filter 4 is provided to conventional rectifiers and filtering capacitors 6 for rectifying the AC signal. The rectifier is preferably a full-wave rectifier of a type known to one skilled in the art and provides a DC output of, for example, approximately 150 volts DC.
The full-wave rectified and filtered DC output from rectifier 6 is provided to the high frequency transformer portion 8 of the battery charger. The high frequency transformer portion 8 includes a charge circuit 12 and a boost circuit 16. The boost circuit 16 is used to provide a high current boost that can be used to jump-start a vehicle with a dead battery. The charge circuit 12 is used for normal charging of the battery. The operation of the boost circuit 16 and the charge circuit 12 may take place sequentially, in any order, or simultaneously. The charge circuit 12 and the boost circuit 16 each include a high frequency transformer 14, 18, respectively. A DC output from the rectifiers and filtering capacitors 6 is provided to each of the high frequency transformers 14, 18.
Transformers typically receive an AC input and provide an AC output. For example, a transformer plugged into an ordinary wall-socket is provided with a 120-Volt AC input and outputs an AC signal that is dependent on the secondary winding of the transformer. Thus, high frequency transformers 14, 18 need to be manipulated to behave so that the DC signal from rectifiers 6 looks like an AC input. This manipulation is accomplished by switching the DC output from rectifier 6 through the high frequency transformers. The transformers are turned on and off at a high frequency, for example, about 20kHz and above. This switching causes the transformers to behave as though their input is AC. This switching can be accomplished using essentially any type of switch, for example, a field effect transistor (FET) or other electronic switch. The high frequency transformers 14, 18 of the illustrated embodiment are switched by switches 22, 24, respectively, coupled thereto. The switches 22, 24 are, in turn, controlled by PWM controllers 23, 25. The PWM controller may be, for example, a TL 494 Motorola type controller or a discrete controller. The PWM controller generates a PWM driving signal for turning the switches on and off.
The charge circuit 12 is capable of operation in two modes, a charge mode and a pulse mode. In the charge mode, the charge circuit 12 operates to charge a battery. In the pulse mode, the charge circuit 12 operates to condition or desulfate a battery. A user may select between one of these two modes via selector 30. The selector 30 provides the user's selection to a pulse enable circuit 28. The pulse enable circuit 28 controls the PWM controller 23 in accordance with whether the charge mode or the pulse mode of operation is selected for the charge circuit 12.
When the pulse mode is selected, the pulse enable circuit 28 controls the PWM controller 23 to alternately be active and output a driving signal to the switch 22 and be inactive and not drive the switch 22. A cycle of enabling/disabling the switching of the switch 22 is repeated under the control of the PWM controller 23. Figure 2 illustrates exemplary output waveforms for the pulse enable circuit 28 and the PWM controller 23. In the pulse mode, the pulse enable circuit 28 is activated such that its output signal W₁ varies between low and high states as shown in Figure 2. The PWM controller 23 is activated depending upon the output signal W₁ of the pulse enable circuit 28. During a first time period t1, the output W₁ of the pulse enable circuit 28 is high and the PWM controller 23 is activated to generate a PWM driving signal W₂, as shown in Figure 2. The driving signal W₂ of the PWM controller 23 is provided to the switch 22, e.g., to the gate of a FET comprising switch 22, to turn it on and off. For example, the driving signal from the PWM controller 23 may have a duty cycle of less than 15% so that the FET is turned on for a very short period of time, outputs current to the battery, and is then disabled. The driving signal modulates the FET. During a second time period t2, the output W₁ of the pulse enable circuit 28 is low and the PWM controller is deactivated. No driving signal is provided to the FET, and the FET remains off. Pulsing of the high frequency transformer in this manner chops its output to condition the battery.
During the pulse mode, a series of output current pulses are generated by the battery charger and are provided to the discharged battery 21. The current pulses may have a frequency of about one pulse per second and a rise time of about 100 volts/microsecond or less.
The battery charger pulses the battery to perform the conditioning. The switching of the FET switch 22 is controlled to generate the conditioning pulses. For example, the microprocessor may enable the PWM controller 23 to switch the FET on and off for a period of time, about 50 microseconds. The PWM controller 23 is then turned off, disabling the FET switch 22. The FET is not switched when the PWM controller 23 is off. The PWM controller 23 may remain off for about 1 second. The process then repeats until the battery conditioning operation has been performed for 24 hours, at which time the battery conditioning process is completed.
When the charge mode is selected via selector 30, the PWM controller 23 is preferably always activated. Operation of the PWM controller 23 may be controlled in part via feedback from the battery 21 being charged. The duty cycle of the driving signal generated by PWM controller 23 is varied based on the charging state of the battery. A feedback signal from the battery being charged 21 to the PWM controller 23 provides the information on the charging state of the battery. The more power the battery needs, the higher the duty cycle; and the less power the battery needs, the lower the duty cycle. Switch 22 switches transformer 14 in accordance with the driving signal to charge the battery 21.
Referring again to Figure 1, boost circuit 16 is now described. Boost circuit 16 provides a high current pulse that can be used to jump-start a vehicle with a dead battery. The boost circuit 16 is enabled via a standard/boost mode selector 26, which a user can actuate. When actuated to select the boost mode, selector 26 enables PWM controller 25 to generate a signal that drives switch 24, which, in an exemplary embodiment, comprises a FET. The frequency of the driving signal for FET 24 in the high power boost circuit 16 can be the same as or different from the frequency of the driving signal for switch 22 in the charge circuit 12, for example, about 20kHz, or even higher. When the same frequency is used, the clock frequency for the PWM controller 23 associated with the charge circuit 12 to be shared by the PWM controller 25 for the high power boost circuit 16.
The high power boost circuit 16 receives a DC input from the rectifier 6. The DC input is provided to high frequency transformer 18 in the high power boost circuit 16. Preferably, the high frequency transformer 18 in the high power boost circuit 16 is separate from the high frequency transformer 14 in the charge circuit 12. The high frequency transformer 18 in the high power boost circuit 16 outputs a relatively high current with respect to the output of the charge circuit 12. For example, the current output from the boost circuit 16 may range from about 30 amps to about 500 amps, compared to about 2-25 amps for the charge circuit 12. Additionally, the output from the boost circuit 16 is typically only generated for a short period of time, for example, about 3-40 seconds. Accordingly, the high frequency transformer 18 in the high power boost circuit 16 is preferably slightly larger than the high frequency transformer 14 in the charge circuit 12.
The high frequency transformer 18 has a duty cycle such that it may be on half the time and off the half the time, even though there may always be an output from the transformer that is rectified, filtered and used to recharge the battery. The PWM controller 25 is typically turned off for about 60-90% of the time and is turned on for about 10-40%, and then it is turned back off again to achieve the duty cycle for the high frequency charger. During the 10-40% of the time the PWM controller 25 is on, switch 24 switches the high frequency transformer. This provides a high current pulse out of the high frequency transformer through rectifier 19 to the battery to be charged.
Both the transformer 14 in the charge circuit 12 and the transformer 18 in the boost circuit 16 output an AC signal that needs to be converted to DC in order to be used by the battery. Therefore, the output of the high frequency charger in the charge circuit passes through standard rectifiers and filtering capacitors 19, 20 to provide a DC output. The high frequency transformer 14 in the charge circuit 12 is preferably a relatively small transformer capable of delivering a relatively low current, preferably between about between 2 and about 30 amperes, and a voltage corresponding to whatever the battery needs, for example, about 14.2 volts. The switching operation for the high frequency transformer 18 in the high power boost circuit 16 by switch 24 is preferably performed in a manner similar to that described above with regard to the charge circuit 12 but, due to its different construction, results in a current output from the boost circuit from about 30 amps to about 500 amps.
Turning now to Figure 3, an example of circuitry that may comprise the pulse enable circuit 28 is described. In the illustrated embodiment, the pulse enable circuit 28 incorporates manual control of the PWM controller 23. A user can thus control the charging of the battery. The PWM controller 23 has an input 31 to which a reference voltage is applied, and a dead time control input 32. The dead time control input 32 controls the duty cycle of the driving signal from output 34 of the PWM controller 23 based on a percentage of the reference voltage that is applied to the dead time control input 32. For example, when the full reference voltage is applied to the dead time control input 32, the duty cycle of the output signal of PWM controller 23 is set to zero, the switch 22 (Fig. 1) is off, and no voltage is applied to the battery being charged. When no voltage is applied to the dead time control input 32, the duty cycle of the output signal of the PWM controller 23 is set to its maximum, and a maximum current is applied to the battery. The duty cycle of the driving signal from output 34 of the PWM controller 23 varies between these two extremes in dependence on the percentages of the reference voltage applied to dead time control input 32.
In the embodiment shown in Figure 3, a combination of a counter circuit 36 and a number of transistors 38-41 is used to control the percentage of the reference voltage that is applied to the dead time control input 32. The counter 36 is preferably either a low active device with diodes or a high output active decade counter, for example a 4017B CMOS IC. Of course other arrangements are possible within the scope of the invention. Outputs of the counter 36 are each connected to transistors. Four transistors 38-41 for four outputs of counter 36 are shown in Figure 3. The number of outputs and corresponding transistors may vary depending upon the type of counter used. Each transistor may be of a BJT or of a FET type. A control electrode of each transistor 38-41 is connected through a corresponding resistor 42-45 to a separate output of the counter 36. A first electrode in the main current path of each transistor 38-41 is coupled to ground. A second electrode in the main current path of each transistor 38-41 is coupled to a resistor 46-49, respectively. Each of the resistors 46-49 is coupled to the dead time control input 32 of the PWM controller 23. Each of the resistors 46-49 is also coupled to resistor 51, which is, in turn coupled to the reference voltage input 30 of the PWM controller 23.
The resistors 46-49, the associated transistors 38-41, and the resistor 51 form a voltage divider. The voltage difference between the reference voltage input 30 and the dead time control input 32 is controlled by the values of the resistors 46-49. For example, each of the resistors 46-49 can be selected to have a different resistance. The voltage drops across the resistors 46-49 will vary accordingly. Thus, the percentage of the reference voltage applied to the dead time control input 32 varies depending on which transistor 38-41 is turned on and the value of its associated resistor 46-49.
For example, as the counter 36 is clocked, one of the outputs of the counter 36 becomes active and turns on the respective transistor 38-41 connected to that output. Only one of the transistors 38-41 may be turned on at any one time. The turned on transistor 38-41 provides a current path from the dead time control input 32, through its respective resistor 46-49, to ground, thereby altering the voltage at the dead time control input 32 with respect to the voltage at the reference voltage input 30. Alternately, more than one of the transistors 38-41 is turned on.
A switch 53, such as a push button switch, may be coupled to a clock input 37 and used to clock the counter 36. For example, actuating the switch once clocks the counter 36 from the zero output to the first output, actuating the switch a second time clocks the counter 36 to the second output, and so on. As each output of the counter 36 becomes active, the transistor associated with that output turns on, altering the voltage at the dead time control input 32. Thus, the duty cycle of the driving signal from PWM controller 23 can be manually stepped through various levels.
In an alternative embodiment, a microprocessor can be provided to replace PWM controllers 23, 25 and pulse enable circuit 28. The microprocessor is programmed to perform the control functions for these elements as described above.
Accordingly, a high frequency charger and method of operating a high frequency charger are provided. The use of high frequency transformers provides several advantages. For example, as long as the switching frequency is high enough, iron is not needed for the core of the transformers. A very light substance, for example, ferrite, can be used, greatly reducing the weight and unwieldiness of known devices. Additionally, the secondary winding of the transformers may have a small number of windings, for example, as few as four turns of wire. In comparison, a conventional transformer can require over 100 turns of wire. The higher the frequency, the less wire is needed, further reducing the cost required to manufacture the device.
The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the art the best way known to the inventors to make and use the invention. It is therefore to be understood that, within the scope of the claims, the invention may be practiced otherwise than as specifically described. For example, the processes described above may be performed in an order different from that described above.

Claims

A high frequency charger, comprising:
a charging circuit (12) including a first high frequency transformer (14);

a first switch (22) switching the first high frequency transformer (14) at a first frequency for producing a charging current for charging a battery (21);

characterized in that the high frequency charger further comprises:
a boost circuit (16) including a second high frequency transformer (18), separate from the first high frequency transformer (14);

a second switch (24) switching the second high frequency transformer (18) at a second frequency for producing a relatively high boost current compared to the charging current for jump-starting a vehicle; and

a selector switch (26)for selectively activating at least one of the charging circuit (12) and the boost circuit (16).
The charger of claim 1, further comprising:
a filter (19, 20) coupled to outputs of the first (14) and second (18) high frequency transformers for passing a DC voltage signal.
The charger of claim 1, wherein the charging circuit (12) has a charge mode and a pulse mode, and further comprising means (30) for selectively activating one of the charge mode and the pulse mode.
The charger of claim 3, further comprising means coupled to the first switch (22) for alternatingly enabling the first switch (22) to switch the first transformer (14) at the first frequency and disabling the first switch (22) from switching the first transformer (14).
The charger of claim 1, further comprising:
a first controller (23) providing a driving signal to the first switch (22); and

a second controller (25) providing a driving signal to the second switch (24).
The charger of claim 5, wherein the selector switch (26) is coupled to the first (23) and second (25) controllers for selectively activating at least one of the first (23) and second (25) controllers.
The charger of claim 5, further comprising a feedback circuit connected between the battery (21) and the first controller (23) for adjusting a duty cycle of the driving signal provided by the first controller (23) based on charging parameters of the battery (21).
The charger of claim 6, wherein the charging circuit (12) has a charge mode and a pulse mode and further comprising a selector (30) coupled to the first controller (23) for selecting between the charge mode and the pulse mode.
The charger of claim 7, further comprising an enable circuit (28) coupled to the selector (30) that selectively enables and disables the first controller (23) at a predetermined rate when the pulse mode is selected.
The charger of claim 2, wherein a DC signal output from the second high frequency transformer (18) has a current of about 25-300 amps.
The charger of claim 2, wherein a DC signal output f rom the second high frequency transformer (18) has a duration of about 3-35 seconds.
The charger of claim 3, wherein, in the pulse mode, a DC output signal of the charging circuit is a series of pulses.
The charger of claim 12, wherein the series of pulses has a rise time of less than 100 volts per microsecond.
The charger of claim 12, wherein the series of pulses has a frequency of about one pulse per second.
The charger of claim 2, further comprising:
a pair of connectors coupled to the filter (19, 20) and adapted for connection to a battery (21);

at least one switch coupled in between one of the connectors and the filter;

a polarity detection circuit coupled to the connectors for determining a polarity between the connectors and providing a polarity signal representing the polarity; and

a microprocessor receiving the polarity signal and generating a signal for opening or closing the switch in dependence on the polarity signal.
The charger of claim 15, wherein the polarity detection circuit includes an opto-isolator.
The charger of claim 15, wherein the at least one switch includes a transistor.
The charger of claim 15, further comprising means for detecting disconnection of the connectors from the battery (21) and opening the at least one switch when disconnection is detected.
The charger of claim 5, further comprising a control circuit coupled to the first controller (23) for setting a duty cycle of the driving signal of the first controller (23).
The charger of claim 19, wherein the control circuit setting a duty cycle comprises:
an integrated circuit; and

at least two reference voltage circuits developing a reference voltage and coupled between the integrated circuit and the first controller, wherein the integrated circuit selectively enables at least one of the reference voltage circuits.
The charger of claim 20, wherein the integrated circuit comprises a counter (36).
The charger of claim 21, wherein each of the reference voltage circuits includes a switch that can be opened and closed in dependence on an output from the counter (36).
The charger of claim 19, wherein the control circuit setting a duty cycle comprises a voltage divider network dividing a voltage applied to a reference voltage input of the first controller (23) and a control input (32) of the first controller (23), wherein the duty cycle varies based on a percentage of the reference voltage applied to the control input (32).
The charger of claim 1, further comprising a computer for controlling the operation of the first (22) and second (24) switches.
The charger of claim 24, wherein the charging circuit (12) has a charge mode and a pulse mode, and further comprising means for selectively activating one of the charge mode and the pulse mode; and a computer-readable information storage medium, the computer-readable information storage medium storing computer-readable program code for causing the computer to perform the steps of:
detecting a selected of mode of operation; and

when a pulse mode is selected:
a) generating a driving signal for the first switch (22) for a first period of time;

b) disabling the first switch (22) for a second period of time; and

c) returning to step a).
The high frequency charger of claim 5, further comprising:
an enable circuit (28) that selectively enables and disables the first controller (23) at a predetermined rate for producing a series of DC pulses as the DC output signal.
The charger of claim 24, further comprising:
a display coupled to the computer for displaying output from the computer; and

input means coupled to the computer for permitting a user to select a mode of operation.
The charger of claim 24, further comprising:
means for detecting at least one of a voltage and a current at an interface of the charger with a battery to be charged; and

a feedback circuit for providing the detected voltage or current to the computer.
The charger of claim 28, wherein the means for detecting comprises an opto-isolator for producing a voltage representing the voltage of the battery while it is being charged by current from the charging circuit.